Modular furnace and methods of repairing same

Abstract

A refractory furnace (10) is constructed to facilitate repair of worn or damaged refractory portions while the furnace is maintained at near-operating temperature. A sidewall (40) of the refractory furnace is comprised of a plurality of modular sections (85) each of which includes a refractory lining (87). One or more modular sections may be selectively replaced when becoming worn or damaged. Replacement is accomplished by external access and removal of the worn or damaged modular sections.

We claim: 
     
       1. A furnace, comprising: a frame; and   a refractory lining which is attached to and supported by said frame, said refractory lining comprising: a bottom portion which forms a leakproof reservoir for holding molten material;   a roof portion which is spaced above said bottom portion; and   a sidewall portion which is disposed between said bottom portion and said roof portion and which comprises a plurality of modular sections which are capable of being removed individually without the need to enter the furnace to permit replacement of individual ones of the modular wall sections.     
     
     
       2. The furnace of claim 1, wherein each said modular section of said sidewall portion includes a plurality of refractory elements which are adhered together to help maintain said elements in the configuration of said modular section. 
     
     
       3. The furnace of claim 1, wherein each said modular section of said sidewall portion includes an external support structure which is supported by a portion of said frame adjacent to said bottom portion of said refractory lining. 
     
     
       4. The furnace of claim 3, wherein each said modular section includes a plurality of refractory elements which are adhered together and wherein said external support structure to which is attached the plurality of refractory elements of a modular section is mechanically secured to a portion of said frame adjacent to said roof portion. 
     
     
       5. The furnace of claim 1, wherein each said modular section of said sidewall portion of said refractory lining comprises a single cast, monolithic refractory element. 
     
     
       6. The furnace of claim 5, wherein said monolithic refractory element is attached to a portion of an external support structure with hangers. 
     
     
       7. The furnace of claim 6, wherein each said external support structure to which is attached a cast monolithic element is in mechanical engagement with a portion of said frame adjacent to said bottom portion. 
     
     
       8. The furnace of claim 6, wherein each external support structure to which is attached a modular section which comprises a cast monolithic element is mechanically secured to another portion of said frame adjacent to said roof portion. 
     
     
       9. A method of repairing a furnace, said method comprising the steps of: providing a furnace which includes a frame, a bottom refractory portion for holding molten material, a roof refractory portion which is positioned above the bottom portion and a sidewall refractory portion which is disposed between the bottom portion and the roof portion and which comprises a plurality of modular refractory sections which are capable of being removed individually without the need to enter the furnace to permit replacement of individual modular wall sections;   from a position external to the furnace, applying forces to a modular section which is in need of replacement to remove the modular section which is in need of replacement from the sidewall portion; and   installing a replacement modular section in place of the removed modular section.   
     
     
       10. The method of claim 9, wherein said method is capable of being performed when the furnace is at an elevated temperature. 
     
     
       11. The method of claim 9, wherein said method is performed when the furnace is at room temperature. 
     
     
       12. The method of claim 9, wherein the modular section is removed by the steps of: disengaging securing means associated with an external support structure of the modular section to which refractory portions are attached from the frame adjacent to the roof portion;   applying a force to the external support structure to facilitate removal of the modular section which is in need of replacement from juxtaposition with adjacent modular sections; and   removing the modular section which is in need of replacement from the furnace.   
     
     
       13. The method of claim 9, wherein removing force is provided by an external mechanical device which is attached temporarily to the external support structure of the modular refractory section which is in need of replacement.